Reassembly

CAUTION: When installing bearings, pistons, or other sliding parts, lubricate contacting surfaces with new engine oil.
Place removed parts such as bearings and bearing caps in their proper order and direction.
When installing connecting rod nuts, and main bearing cap bolts, apply new engine oil to threads and seating surfaces.
Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate.


Assembly

PISTON
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring.
- Align the direction of piston and connecting rod.
- Numbers stamped on connecting rod and cap correspond to each cylinder.
- After assembly, make sure connecting rod swings smoothly.






3. Set piston rings as shown.

CAUTION: When piston rings are not replaced, make sure that piston rings are mounted in their original positions.






When replacing piston rings, these without punchmarks, present, piston rings can be mounted with either side up.






Align piston rings so that end gaps are positioned as shown in the figure.








OIL JET
Install oil jets.

Insert oil jet knock pin into the cylinder block knock pin hole, and tighten the mounting bolts.







CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and main bearing beam.
Confirm that correct main bearings are used.

2. Instructions for re-use of main bearing cap bolts.






A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in the figure.

d2:............Select minimum diameter in the measuring area.

If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones.

Limit (d1 - d2): ............0.11 mm (0.0043 inch)









3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as shown.
Make sure that the front mark on the main bearing beam faces the front of the engine.

Tightening procedure
a. Tighten all bolts to ............32 to 38 Nm (3.3 to 3.9 kg-m, 24 to 28 ft. lbs.).
b. Turn all bolts 9............0 to 95 degrees clockwise with angle wrench.

Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.
After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
Lubricate threads and seat surfaces of the bolts with new engine oil.






4. Measure crankshaft end play.

Crankshaft end play:
Standard ............0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit ............0.30 mm (0.0118 inch)

If beyond the limit, replace bearing with a new one.






5. Install connecting rod bearings in connecting rods and connecting rod caps.
Confirm that correct bearings are used.
6. Install pistons with connecting rods.






a. Install them into corresponding cylinders with Tool.
Be careful not to scratch cylinder wall with the connecting rod.
Arrange so that front mark on piston head faces toward engine front.






b. Install connecting rod caps.
Lubricate threads and seat surfaces with new engine oil.
Install so that the cylinder number stamped on the connecting rod agrees with that stamped on cap side.
Make sure that front mark on the connecting rod cap faces the front of the engine.






c. Re-use connecting rod cap bolts as follows.
Make sure that the bolts can be smoothly screwed-in to the end manually.
If not, measure the outer diameter "d" shown in the figure.

Outer diameter "d" of connecting rod cap bolt:
Standard ............7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit ............7.75 mm (0.3051 inch)






d. Tighten connecting rod cap bolts to the specified torque.

Connecting rod cap bolt:
1. Tighten nuts to .............19 to 21 Nm (1.9 to 2.1 kg-m, 14 to 15 ft. lbs.).
2. Turn nuts ............90 to 95 degrees clockwise with angle wrench.






7. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit 0.40 mm (0.0157 inch)
If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.







REPLACEMENT OF PILOT CONVERTER
1. Remove pilot converter using tool or suitable tool.






2. Install pilot converter as shown.


DRIVE PLATE
Install drive plate.





Install the drive plate and reinforce plate in the direction shown in the figure.
Secure the crankshaft using a ring gear stopper.
Tighten the installation bolts crosswise over several times.